Wyco Manual New-quark:Gomaco Manual New-quark…catalog.jamiesonequipment.com/Asset/WYCO Hydraulic...

Operation and

Service Manual

for

WYCO

Hydraulic Paving

Vibrators

Jamieson Equipment Companywww.jamiesonequipment.com

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CHAPTER 1 - GE�ERAL I�FORMATIO� .....................................................................................................................................1

a) Purpose of Vibration ..............................................................................................................................................................1

b) Vibrator Positioning and Spacing .........................................................................................................................................1

c) Vibrator Speed (VPM) Vibrations Per Minute ......................................................................................................................1

d) Paver Travel Speed ................................................................................................................................................................1

e) Mix Design and Slump ..........................................................................................................................................................1

CHAPTER 2 - VIBRATOR DESIG� FU�DAME�TALS ...............................................................................................................2

a) Rotor ......................................................................................................................................................................................2

b) Bearings and Bearing Cups ..................................................................................................................................................2

c) Hydraulic Motor ....................................................................................................................................................................2

d) Square Head Housing ............................................................................................................................................................2

e) Oldham Style Drive Components .........................................................................................................................................2

f) Vibration Isolator ..................................................................................................................................................................2

g) Hydraulic Hoses and Quick Disconnects ..............................................................................................................................2

h) Protective Hoses and Plugs ...................................................................................................................................................3

CHAPTER 3 - I�STALLATIO� A�D OPERATI�G REQUIREME�TS .....................................................................................4

a) Mounting Vibrators.................................................................................................................................................................4

b) Hydraulic Hose Connections ................................................................................................................................................4

c) Oil Filtration ..........................................................................................................................................................................4

d) Vibrator Performance and Oil Supply ..................................................................................................................................4

Oil Pressure .................................................................................................................................................................4

Temperature .................................................................................................................................................................4

Flow Rate ....................................................................................................................................................................5

e) Trouble Shooting ...................................................................................................................................................................5

Trouble Shooting Chart ...............................................................................................................................................6

f) Vibrator Parts Breakdown.......................................................................................................................................................7

Straight Vibrator............................................................................................................................................................7

Angle Vibrator...............................................................................................................................................................8

Vibrator Assembly Parts List........................................................................................................................................9

CHAPTER 4 - SERVICE A�D ASSEMBLY I�STRUCTIO�S ....................................................................................................10

a) Maintenance Interval ..........................................................................................................................................................10

b) Special Tools Required .......................................................................................................................................................10

c) Bearing Replacement ..........................................................................................................................................................10

1) Head Housing Removal .......................................................................................................................................10

2) Rotor Assembly Removal .....................................................................................................................................10

3) Rotor Disassembly ................................................................................................................................................11

4) Cleaning ...............................................................................................................................................................11

5) Bearing Replacement ...........................................................................................................................................11

6) Rotor / Square Head Housing Assembly .............................................................................................................12

d) Hydraulic Motor Seal Replacement ....................................................................................................................................13

1) Seal Removal ........................................................................................................................................................14

2) Seal Replacement .................................................................................................................................................14

e) Hose, Hydraulic Motor and Alternate Hydraulic Motor Seal Removal .............................................................................14

1) Protective Hose Removal .....................................................................................................................................15

2) Motor Housing Removal ......................................................................................................................................15

3) Hydraulic Motor Removal ...................................................................................................................................15

4) Alternate Seal Replacement ..................................................................................................................................16

f) Assembly .............................................................................................................................................................................16

1) Hydraulic Motor to Motor Housing Assembly .....................................................................................................16

g) Speed Sensing / Smart Vibrators .........................................................................................................................................17

CHAPTER 5 - PARTS DRAWI�GS .................................................................................................................................................18

.TABLE OF CO�TE�TS


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CHAPTER 1

GE�ERAL I�FORMATIO�

a) Purpose of Vibration

The use of internal vibration is required to

improve the workability of low slump con-

crete used in slip form paving. Low slump

concrete reduces edge slump conditions,

which allows the concept of slip form paving

to work. Also, lower slump concrete general-

ly means a lower water to cement ratio, which

increases pavement strength. Vibration

increases the workability of concrete by flu-

idizing it and helps to provide a smooth work-

able surface. Equally important, it consoli-

dates the concrete reducing entrapped air,

honey combing, cold jointing and other inter-

nal flaws which would reduce pavement

strength.

b) Vibrator Positioning and Spacing

Proper positioning and operation of vibrators

in the paving slip form molds is important to

provide proper consolidation of the concrete.

Generally, the distance between vibrators

should be between 12 and 24 inches depend-

ing on mix design, paver speed, vibrator speed

and numerous other factors.

The proper position of the vibrators should be

with their tips angled downward slightly and

as close to the center of the slab as possible.

With the vibrator tip angled down into the

center of the slab, the opening created by the

vibrator will have a tendency to fill with a

more uniform mixture. Also, the highly

vibrated concrete directly next to the vibrator

will be spread over a larger area reducing the

chance of localized over-vibration. The angle

also helps to increase the area vibrated by not

directing vibration straight down into the

subbase.

c) Vibrator Speed (VPM) Vibrations per

Minute

Historically, vibrator speed has been between

5,000 and 10,800 VPM, although in some

areas, the trend is to reduce speeds to

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between 5,000 and 8,000 VPM. As with

vibrator spacing, the optimum vibrator speed

depends on many factors. These include,

but are not limited to mix design, paver speed

and vibrator spacing. Regardless of what

optimum speed is required it is important to

closely monitor vibrator speed to ensure a

consistent quality and more uniformly

consolidated pavement.

d) Paver Travel Speed

Paver travel speed will affect consolidation.

If the paver speed is too high, the vibrators

may not be vibrating in the mix for a long

enough duration to adequately consolidate it.

If the paver travel speed is too slow, over-

vibration will occur, driving entrained air out

and segregating the mix.

e) Mix Design and Slump

Mix design and slump have an influence on

concrete consolidation. A high slump concrete

will consolidate easier than a low slump

concrete. However, if the slump is too high

it will cause edge slump problems and lower

the strength of the concrete. If the mix

consists of fine aggregate and one size of large

coarse aggregate, it will be harder to

consolidate and finish the slab. It is

recommended to use a mix that uses at least

two aggregate sizes, one large and one small.

The smaller aggregate mixed in with the larger

aggregate will fill some of the larger voids,

thus making finishing and consolidation

easier.


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CHAPTER 2

VIBRATOR DESIG� FU�DAME�TALS

a) Rotor

The rotor is the component that generates

vibration. A vibration impulse is generated

every revolution. It is essentially a shaft with

material removed from one side to create an

unbalance. The greater the unbalance, the

greater the centrifugal force that can be gener-

ated. The following lists the potential cen-

trifugal forces generated by the rotor at differ-

ent speeds:

Speed VPM Force 2000# 2500#

5,000………… 448 562

6,000………… 677 809

7,000………… 877 1,101

8,000………… 1,145 1,438

9,000………… 1,450 1,820

10,000………… 1,790 2,247

10,800………… 2,088 2,621

b) Bearing and Bearing Cups

Two bearings are located on each end of the

rotor. Each bearing is individually sealed and

lubricated with high temperature grease. The

bearings are separated from each other by a

shim, which prevents interaction between the

bearing outer races. The bearing inner races

and shims are clamped together on both ends

of the rotor using threaded components. The

bearings fit into high precision ground bearing

cups. The clearance between the bearing

outer diameters and the bearing cup inner

diameters is extremely small. A hardened cup

is permanently pressed into the head housing.

The other cup is slotted to prevent rotation

and it mates with the motor housing.

c) Hydraulic Motor

Forcing hydraulic oil through it operates the

Hydraulic Motor. The oil passes between two

gears, causing the output shaft to turn. The

output shaft is centered on the motor. A gear

is internally mounted on the output shaft and

mates with an idler gear. A lip seal assembly

is used to seal between the aluminum

hydraulic motor housing and the output shaft.

Controlling the oil flow through the motor can

control the motor speed.

d) Square Head Housing

The Square Head Housing has four flat sides

which are beneficial for transmitting vibration

to the mix. It supports the rotor through the

bearings and bearing cups. The external sur-

faces are case hardened for wear resistance.

e) Oldham Style Drive Components

The components that transmit rotation from

the hydraulic motor to the rotor are of a

design known as Oldham drive. These com-

ponents allow for a slight misalignment

between motor and rotor axes of rotation. The

output shaft from the hydraulic motor has two

flat parallel surfaces. These flat surfaces mate

with a slot in the driver. The driver also has

flat surfaces, which mates with the slot in the

driver sleeve. The driver sleeve screws on to

the end of the rotor. The drive slots are

located 90 degrees from each other. Small

amounts of misalignment are compensated for

with a small amount of relative motion

between the flats and the slots.

f) Vibration Isolator

The rubber vibration isolator is used to

reduce transmission of vibration to the mount-

ing bar of the paver. It allows for a small

amount of relative motion required to create

vibration while maintaining support for the

vibrator.

g) Hydraulic Hoses and Quick Disconnects

Two hydraulic hose connections are required.

The pressure hose is the smaller diameter hose

and it supplies hydraulic oil to the vibrator.

The return hose is the larger diameter hose

and hydraulic oil exits through it. Quick

disconnects are used on the end of each

vibrator hose. Generally, the female quick

disconnect is attached to the pressure line.


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The quick disconnects can be attached to each

other when removed from the machine to

prevent contamination.

h) Protective Hoses and Plugs

A rubber protective hose surrounds the

hydraulic hoses leaving the vibrator,

preventing wear due to concrete abrasion.

This protective hose is attached to the vibrator

with hose clamps. A rubber plug supports the

hydraulic hoses where the hydraulic hoses

leave the vibrator, preventing it from rubbing

against metal. Another plug is located where

the hydraulic hoses leave the protective hose.

This plug primarily is used to prevent foreign

material from entering the protective hose.

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CHAPTER 3

I�STALLATIO� A�D OPERATI�G

REQUIREME�TS

a) Mounting Vibrators

See figure line art drawings for illustrations of

item numbers listed in parenthesis.

Angle bracket mounted vibrators are intended

to be mounted on a round bar having an

outside diameter of 2” to 2-7/8”. Generally

the vibrator tip should be angled downward 15

to 30 degrees. Attach the top clamp (23)

around the mounting bar and tighten the two

bolts (24), nuts (20) and lock washers (19).

Straight bracket mounted vibrators (page 9)

should be mounted with two isolators.

b) Hydraulic Hose Connection

The hydraulic hoses exiting the vibrator are

supplied with quick disconnects. Normally

the male quick disconnect is attached to the

pressure line, but this can vary. The smaller

diameter hose is the pressure. Always ensure

that these hoses are attached accordingly or

the oil seal in the hydraulic motor will fail

very quickly.

THE SEAL O� THE HYDRAULIC

MOTOR WILL FAIL QUICKLY IF THE

HOSES ARE IMPROPERLY

CO��ECTED.

E�SURE THAT THE QUICK

DISCO��ECTS ARE CLEA� PRIOR TO

ASSEMBLY OR LEAKAGE MAY

OCCUR. WHE�EVER A VIBRATOR IS

�OT CO��ECTED TO A PAVER,

CO��ECT THE PRESSURE A�D

RETUR� LI�ES TOGETHER TO AVOID

CO�TAMI�ATIO�.

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IT IS IMPORTA�T TO MI�IMIZE THE

AMOU�T OF HOSE CO��ECTED TO

THE RETUR� LI�E. EXCESSIVE

AMOU�TS OF RETUR� HOSE WILL

I�CREASE BACK PRESSURE O� THE

HYDRAULIC MOTOR SEAL, CAUSI�G

PREMATURE HYDRAULIC MOTOR

SEAL FAILURE.

c) Oil filtration

The hydraulic oil must be properly filtered to

ensure proper operation and to prevent wear

and damage due to contaminates.

IT IS IMPORTA�T THAT THE

HYDRAULIC FLUID BE PROPERLY

FILTERED TO 10 MICRO� ABSOLUTE

(ISO 17/13 FLUID CLEA�LI�ESS). OIL

THAT IS �OT PROPERLY FILTERED

MAY CAUSE DAMAGE TO THE

HYDRAULIC MOTOR.

d) Vibrator Performance and Oil Supply

Oil Pressure

Oil pressure will vary depending on oil tem-

perature, flow rate, oil viscosity and the

amount of hose connected between manifold

and vibrator. A vibrator in good condition

should operate with a pressure of 700 PSI to

1200 PSI at 4 GPM and 140° F.

Temperature

The hydraulic oil temperature should be

maintained between 100° F and 180° F

with 140° F being optimum.

U�DER 100°F, EXCESSIVE PRESSURE

IS REQUIRED TO OPERATE THE

VIBRATOR AT �ORMAL SPEEDS.

TEMPERATURES ABOVE 196° F


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the most. The rule then can be read giving the

operating speed.

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COULD CAUSE SERIOUS DAMAGE.

WHE� EXCESSIVE TEMPERATURES

ARE E�COU�TERED, FOLLOW THE

PAVER MA�UFACTURI�G RECOM-

ME�DATIO�S TO REMEDY THE

SITUATIO�.

Flow Rate

The flow rate of the hydraulic oil through the

vibrator directly affects the speed of the vibra-

tor. When the flow is increased or decreased

the vibrator speed increases or decreases,

respectively. Oil temperature, oil viscosity

and the condition of the vibrator can affect the

relationship between flow and vibrator speed.

Typical vibrator speed at 4 GPM is approxi-

mately 10,800 VPM and typical vibrator

speed at 3 GPM is approximately 8,100 VPM.

e) Trouble Shooting

To aid in trouble shooting the following tools

are available from Wyco Tool:

Hydraulic Test Kit

(Wyco PN 419850)

This kit can measure pressure and flow in

either the pressure or return line of the

vibrator. It mates with the standard vibrator

quick disconnects.

Vibrating Reed-Type Tachometer

(Wyco PN 419855)

This is a reed type tachometer that quickly

measures vibration speed when put in contact

with the rubber protective hose close to the

vibrator. When put in contact, the reed that

vibrates the most is the operating speed.

Slide Rule Tachometer

(Wyco PN 001000)

This is a less expensive alternative to the

tachometer above. It is slightly more

difficult to use and more fragile, but it will

provide an accurate reading. When put in

contact with the rubber protective hose near

the vibrator, a wire is extended until it deflects


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TROUBLE SHOOTI�G CHART

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Trouble Possible Causes Solutions

Vibrator not running 1) Required oil flow and pressure not supplied 1) Supply required oil flow and pressure

2) Failed bearings 2) Replace eccentric bearings per Chapter 4,

Section c

3) Hydraulic motor locked up 3) Replace hydraulic motor per Chapter 4,

Section e

Vibrator running slow 1)Vibrator head full of oil 1) Replace hydraulic motor shaft seal per Chapter 4,

Section d and bearings per Chapter 4, Section c

2) Required oil flow and pressure not supplied 2) Supply required oil flow and pressure; Check

pressure setting on relief valve

3) Hydraulic motor worn internally 3) Remove and replace hydraulic motor

Oil found in protective hose 1) Hydraulic hose connections loose near vibrator 1) Check NPT threads, apply Teflon tape and tighten

2) Hydraulic hose or hose fittings damaged 2) Replace damaged hose or hose fittings

3) Hydraulic motor shaft seal leaking and seal 3) Replace hydraulic motor shaft seal per Chapter 4,

around outside of motor also leaking Section d and replace seal on outside of motor


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HYDRAULIC VIBRATOR ASSEMBLY PARTS LIST

PART �UMBER

ITEM QTY U/M DESCRIPTIO� STRAIGHT

949-100

A�GLE

949-170

1 1 EA SQUARE Head Housing with Lower Bearing Cup 589-400 589-400

2 1 EA Hex Nut 432707 432707

3 1 EA Washer 887011 887011

4 4 EA Bearing 419661 419661

5 2 EA Shim 419697 419697

6 1 EA Rotor 719660 719660

7 1 EA Upper Bearing Cup, Slotted 419668 419668

8 1 EA Spacer 419666 419666

9 1 EA Driver Sleeve 419659 419659

10 1 EA Driver 419656 419656

11 3 EA Socket Head Cap Screw (No. 10-32 x 7/8 inch long) 419660 419660

12 3 EA Lock Washer (No. 10 split ring) 415362 415362

13 1 EA Hydraulic Motor Housing 589404 589403

14 1 EA Hydraulic Motor 418-000 418-000

15 1 EA Hydraulic Hose Assembly (1/4 hose with 1/4 NPT male threads) 8’ - 212508

16 1 EA Hydraulic Hose Assembly (3/8 hose with 3/8 NPT male threads) 8’ - 213708

17 1 EA Angle Mounting Bracket - 419771

18 2 EA Hex Head Bolt - 439712

19 4 EA Lock Washer(1/2 inch split ring) - 439704

20 4 EA Hex Nut (1/2-13) - 439703

21 1 EA Isolator - 419720

23 1 EA Clamp - 419729

24 2 EA Hex Head Bolt (1/2-13 x 3-1/2 inch long) - 439708

25 1 EA Rubber Plug, Tapered - 419684

26 1 EA Punch Lock Clamp - 259601

27 4 FT Protective Hose - 219500

28 1 EA Name Plate 669600 669600

29 1 EA Hose Clamp (No. 36) - 259611

30 1 EA Rubber Plug (No. 11), Straight 419685 419685

31 1 EA Quick Disconnect Set 419692 419692

32 6 FT Protective Hose 219500 -

33 3 EA Hose Clamp (No. 36) 259611 -

34 1 EA Hydraulic Hose Assembly (1/4 hose with 1/4 NPT male threads) 9’ 212509 -

35 1 EA Hydraulic Hose Assembly (3/8 hose with 3/8 NPT male threads) 9’ 213709 -

MOTOR SPECIFICATIO�S A�D HYDRAULIC REQUIREME�TS

DATA BELOW IS BASED IN 225 SSU HYDRAULIC FLUID

FLOW: 4 GPM

PRESSURE: 700 P.S.I.; Max. 1200 P.S.I. with oil at 130° F

INLET: ¼" NPT

OUTLET: 3/8" NPT

FILTRATION: 10 Micron Absolute (ISO 17/13 Fluid Cleanliness)

FLUID TEMP: 100° F Minimum; 180° F Maximum

�OTE: A. DO �OT OPERATE ABOVE 10,800 VPMB. ALWAYS DISCO��ECT I�LET (1/4) HOSE FIRSTC. TO E�SURE PROPER HYDRAULIC MOTOR SEAL LIFE, MAI�TAI� A BACK PRESSURE

TO THE MOTOR OF LESS THA� 50 PSI.D. MALE A�D FEMALE QUICK DISCO��ECTS MAY BE O� EITHER THE PRESSURE OR

THE RETUR� LI�E. ALWAYS CHECK THAT THE SMALLER DIAMETER HYDRAULIC HOSE IS THE PRESSURE HOSE.


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CHAPTER 4

SERVICE A�D ASSEMBLY I�STRUCTIO�S

a) Maintenance interval

It is recommended that Wyco vibrators be

maintained at regular intervals. The

recommended maintenance interval for

vibrators operated between 8,000 VPM and

10,800 VPM is 600 hours. The recommended

maintenance interval for vibrators operated

under 8,000 VPM is 1,200 hours. These

instructions should be followed for

preventative maintenance, which includes

bearing and hydraulic motor seal replacement.

b) Special Tools Required

33 inch pipe wrench

2 inch Girth-Grip toothless pipe wrench

(straight vibrators)

3 inch Girth-Grip toothless pipe wrench (angle

vibrators)

Punch Lock clamp set

Tapered guide (used for hydraulic motor seal

installation, Wyco Tool #419754)

Large crescent wrench which opens to

2-3/8"

c) Bearing replacement

1) Head Housing Removal

See figure 1 or 2 for illustrations of item

numbers listed in parentheses.

Clamp the hydraulic motor housing (13)

in the pipe jaws of a vise. Using a large

crescent wrench, loosen the square head

housing (1) from the motor housing

(right hand threads). Unscrew until the parts

can be easily turned by hand.

2) Rotor Assembly Removal

Clamp the flats of the driver sleeve (9) in a

vise. Pull the head housing (1) off of the

rotor assembly.

�ote: If there is hydraulic oil in the head,

the seal on the hydraulic motor (14) needs

to be changed as described in Section d.

If the hydraulic motor shaft cannot be turned

by hand, the motor may be locked and may

require replacement, as described is Section e.

If the rotor does not come out by hand it needs

to be tapped off. Tap on the open end of the

square head housing (1) with a rubber

hammer while rotating the housing 90 degrees

every couple of taps. Do not damage the end

of the head housing by hitting it directly with

a hammer. If the rotor is stuck in the housing,

a piece of wood can be used to protect the

head housing threads while using a hammer to

dislodge the rotor assembly.


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3) Rotor Disassembly

Clamp the rib of rotor (6) in a vise. Unscrew

the driver sleeve (9) (left hand thread).

Remove the spacer (8) from the rotor.

Remove the upper bearing cup assembly from

the rotor assembly. Press the bearings (4) and

shim (5) out of upper bearing cup (7).

Unscrew the hex nut (2) from the opposite end

of the rotor (left hand thread). Remove

washer (3), the remaining two bearings and

.005 inch thick shim.

4) Cleaning

Prior to assembly, ensure all of the parts are

cleaned and free of foreign material. Inspect

hoses for any damage and replace when

necessary.

�ote: Clean parts to prevent binding

during assembly. Contamination may

cause early failure of bearings.

If reusing the upper bearing cup (7), polish the

inside with Scotch Brite to remove

discoloration. Also, ensure that the inside of

the square housing (1) is thoroughly cleaned.

Replace isolator if broken or rubber is split or

worn.

�ote: It is recommended that new

bearings and shims always be installed

when rebuilding a vibrator. Regreased

bearings will not last as long as new

bearings.

5) Bearing replacement

Clamp the rib of the rotor (6) in a vise. If

the rotor has been previously used, polish the

shafts that the bearings fit over with Scotch

Brite. Slide a bearing (4) onto the rotor end

with the shortest length of thread. The writing

on the outer race of the bearing should face

toward the rotor. Then slide a .005 inch thick

shim (5) onto the rotor.

�ote: Do not use more than one shim

between bearings.

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Slide another bearing onto the rotor with the

writing on the outer race facing away from the

rotor and the other bearing.

Slide a washer (3) onto the rotor. Note that

the washer is thinner than the spacer (8) used

on the other end of the rotor.

Securely tighten hex nut (2) on the end of the

rotor (left hand thread).

Repeat the bearing/shim/bearing assembly on

the opposite end. Slide spacer (8) onto the

rotor. Securely tighten driver sleeve (9) on the

end of the rotor (left hand thread).

6) Rotor Square Head Housing Assembly

Install the upper bearing cup (7) over the

bearings on the driver sleeve (9) end of the

rotor assembly.

Clamp the motor housing (13) in a vise with

the motor shaft facing upward. Apply a

liberal amount of grease to both ends of driver

(10) where the driver contacts the driver

sleeve slot and the hydraulic motor drive shaft.

Insert the driver into the driver sleeve. The

grease will hold the driver in place during

assembly. Hold the rotor vertically with the

driver pointing downward. Align the rotor so

the slot in the driver lines up with the flat

surfaces on the shaft of the hydraulic motor.

Also align the upper bearing cup (7) slot to

mate with the motor housing (13).

Engage the driver with the hydraulic motor

shaft.


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Once the rotor is engaged to the motor

housing, slide the head housing over the rotor

and begin to engage the threads.

Apply No. 2 Permatex on the motor housing

theads. Place the square head housing over the

rotor assembly and screw onto the motor

housing by hand until snug (right hand

thread).

Clamp the bracket in the pipe clamps of a vise

and tighten the head housing.

d) Hydraulic Motor Seal Replacement

The Wyco hydraulic motor will provide

thousands of hours of life under normal

service conditions. However, if hydraulic oil

is contaminated or fluid temperature is not

maintained below 180° F, then premature

failure of motor shaft seals or motor efficiency

degradation will occur. If back pressure in the

return line is greater than 50 PSI, premature

failure of the motor shaft may occur.

If hydraulic oil is found in the square head

housing, the hydraulic motor seal has worn

and requires replacement.

If more than 5 GPM is required to turn 10,000

VPM and the oil temperature is 140° F or

less, then the hydraulic motor efficiency has

fallen below 80 percent and it should be

replaced.


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Seals

1) Seal Removal

It may be possible to remove the hydraulic

motor seal assembly without removing the

hydraulic motor from the vibrator assembly.

This procedure is described below. In the

event that it doesn't work, proceed to

Section e.

With the square head housing (1) removed

from the vibrator assembly, reach into the

motor housing with snap ring pliers and

remove the retaining ring (see drawing #

419747). The seal assembly may be

removed by connecting the return line

hydraulic hose (16) (largest hose) to a

100-psi pressure regulated air supply.

I�JURY MAY RESULT FROM

IMPROPER REMOVAL OF SEAL.

FOLLOW THESE I�STRUCTIO�S

CAREFULLY.

Shut off the air supply with a quick opening

valve. Use an appropriate quick disconnect or

threaded connector to attach the air supply to

the return line (largest of the two hoses). Hold

the open end of the motor housing firmly

against the floor or other hard surface in case

the seal breaks free suddenly. Quickly open

the valve to dislodge the seal from its seat. If

the seal does not come out proceed to Section

e for information on how to remove the motor

for seal removal and closer inspection.

. 2) Seal Replacement

Place a tapered guide over the hydraulic motor

(14) shaft (Wyco tool part # 419754).

Assembly without the tapered guide could tear

the seal lip and cause leakage.

Lubricate the seal lip and O-ring with STP or

clean hydraulic oil and press the seal assembly

into the motor. Be sure that the lip end of the

seal faces toward the motor. Replace the

retaining ring and return to Section c6 if

bearings have already been replaced, otherwise

return to Section c2.

WARNING!! !


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e) Hose, Hydraulic Motor and Alternate

Hydraulic Motor Seal Removal

1) Protective hose removal

Loosen or remove the hose clamp (29)

from the end of the protective hose (27).

Remove the rubber plug (30) from the end of

the protective hose.

Generally, the protective hose (27) and the

hose clamp (29) need to be cut off. Take care

not to damage the hydraulic hoses (15,16).

Remove the rubber plug (25) from the upper

end of the mounting bracket.

Clamp the bracket (17) in a vise and

unscrew the motor housing (13) (right

hand thread) using a Girth-Grip wrench or

pipe wrench.

�ote: The hydraulic hoses need to turn

with the motor housing inside the angle

bracket while unthreading.

Unscrew the hydraulic hoses attached to the

motor and install temporary ¼ NPT and 3/8

NPT plugs to prevent dirt from entering

hydraulic motor.

2) Motor Housing Removal

Clamp the hydraulic motor housing (13)

in the pipe jaws of a vise. Using a large

crescent wrench, loosen the square head

housing (1) from the motor housing

(right hand threads). Unscrew until the parts

can be easily turned by hand.

3) Hydraulic Motor Removal

To remove hydraulic motor (14) from the

motor housing (13), clamp the motor

housing in a vise and remove the three socket

head cap screws (11) and lock washers (12).

�ote: Never clamp the hydraulic motor

in vise or apply wrenches to it. The

hydraulic motor is made of aluminum and

any deformation can cause internal

damage.

If there has been silicon sealant applied, peel

off the sealant at the hydraulic motor to

motor housing interface. Thread a matching

2 or 3 inch long pipe nipple into each port of

the hydraulic motor and hand tighten. Clamp

both nipples close to the


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Wyco Tool Company

motor between the jaws of a large crescent or

pipe wrench and rotate the motor in either

direction to break the silicone sealant that

was applied to the motor to housing interface.

Clean all sealant residue from the parts.

4) Alternate Seal Replacement

Repeat the process described in Section d with

the hydraulic motor removed from the motor

housing (13). Replace the seal as described

in Section d. If the seal does not come out,

repeat the process using a hydraulic hand

pump.

f) Assembly

1) Hydraulic Motor to Motor Housing

Assembly

Rotate the shaft coming out of the hydraulic

motor (14) by hand to insure that the hydraulic

motor is not locked internally (temporary

plugs may have to be loosened). Place the

hydraulic motor into motor housing (13).

Be sure the O-ring on the hydraulic motor is

in its proper position and is not damaged.

Lubricate with light coat of hydraulic oil

before inserting. Rotate the motor on the

housing until the three holes in the hydraulic

motor align with the holes in the motor

housing. Thread in one socket head cap

screw (11) with a lock washer (12). Clamp

the other housing in a vise and thread the other

two cap screws and lock washers in place.

Tighten all three screws securely. Add a bead

of Dow Corning RTV 732 silicon rubber

sealant or equivalent into the space between

the motor housing and the hydraulic motor.

Thread the hydraulic hoses (15 and 16) into

the hydraulic motor using three wraps of

Teflon tape on the threads.

�ote: Do not over tighten the hose

fittings into the hydraulic motor. Over

tightening could cause the aluminum

motor to crack.

Apply No. 2 Permatex to the threaded end of

motor housing (13). Insert the hoses into the

angle bracket and screw the motor housing to

angle bracket (17).

�ote: The hydraulic hoses need to turn

with the motor housing inside the angle

bracket while tightening.

Install the rubber plug (25) around the

hydraulic hoses and tap into place in the angle

bracket.

Tighten the motor housing to the angle

bracket using a Girth Wrench or pipe

wrench.

*Applying silicon sealant is optional


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Wyco Tool Company

Install the protective hose (27) completely

onto the hose barb of the angle bracket.

Position the Punch Lock Clamp (26) over the

protective hose about ¼ inch apart over the

hose barb section.

Tighten and lock the clamp according to the

manufacturer’s instructions.

Install the rubber plug (30) around the

hydraulic hoses at the opposite end of the

protective hose and tap in until it is flush with

the end.

Install one hose clamp (29) directly over the

rubber plug at the end of protective hose

(27) and tighten. Reuse the nameplate (28)

with the remaining hose clamp. Impression

stamp the service date on the nameplate for

future reference.

If bearings have been replaced, replace the

square housing assembly. Return to Section

c6 for assembly instructions. If bearings have

not been replaced go to Section c2.

g) Speed Sensing/Smart Vibrators

When Wyco Tool supplies vibrators that have

the speed sensing option, a cable exits the

back of the hydraulic motor next to the

hydraulic hoses. This armored and shielded

cable (Wyco # 420-005) extends 9 feet away

from the hydraulic motor. It runs parallel to

the hydraulic hose and inside the protective

hose. When the protective hose is greater than

8 feet, an extension cable will be needed to

exit the rubber plug.


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Form #W110

Printed in U.S.A. 8/06


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